gea a-tec spiral freezers and chillers · 2020-05-19 · spiral freezers and chillers guarantee...

GEA A-Tec · 1

GEA A-Tec spiral freezers and chillers

Hygienic food processing

2 · GEA A-Tec

GEA A-Tec · 3

Optimum freezing and chilling solutions

We have developed a highly configurable, versatile freezer and

chiller portfolio that can provide the ideal solutions for your

most complex industrial freezing and cooling needs.

GEA freezer technologies for the food industry exploit our

innovative CALLIFREEZE® technology, which continuously

monitors the condition of products exiting the freezer, and

automatically adjusts the freezer parameters. This constant

surveillance and adjustment help to ensure optimum conditions

for your products, and reduced energy consumption.

Backed by decades of proven knowhow in food freezing and

chilling, our experts can customize freezer and chiller solutions

that will meet your most stringent requirements for safety and

hygiene, cost and energy efficiency. All our technologies are

designed to offer top reliability and performance, and long-term

sustainability. Talk to your local GEA representative to find out

more about our dedicated technology center, where you can

work with our specialists to trial your products on the latest

GEA freezer and chiller equipment.

Here at GEA we understand that the food processing industry needs to stay innovative and develop new recipes and processes that meet rapidly changing consumer demands. You expect robust and reliable freezer and chiller solutions that can help to ensure high quality chilled and frozen food products, at every processing stage.

Extensive experience in freezing and chilling for food processing

4 · GEA A-Tec

A-Tec capacity range

2,000 lb/h 14,000 lb/h

COMPACT MODULAR

Fully built, shipped, Plug-in ready Site built1,500 lb/h

Customized solution

• Modular configuration

• Belt, floor, and enclosure type options to match application

requirements

• Extended run-time from single shift to 14 days operation with

proven frost management systems: Static Pressure Control

System (SPCS) and Sequential Defrost (SD) options

• Low profile top drive option addresses space and headroom

constraints

Safe product handling

• Open profiles and fully welded structure

• Design answers the most stringent hygiene requirements with

fully welded floor and fully welded enclosure option

• Effective solutions from belt cleaning to full recirculating

cleaning system that acts like a giant dishwasher

• Option for fan and drive motors sited outside the enclosure

for improved access and hygiene

High yield with horizontal airflow

• Even airflow and temperature distribution across all tiers for

optimum heat transfer and minimum product dehydration

• High performance, independent from product loading

variation

Low total cost of ownership

• Optimized evaporating temperature for minimum energy

consumption

• Simple drive system, non-proprietary parts, reliable structure

for low maintenance costs

• Option for external fan motors for ease of maintenance

GEA A-Tec spiral freezers are designed to match the needs of your product characteristics, production planning, facility space and line layout.

Superior hygiene by design, high uptime and product yield

GEA A-Tec · 5

models available with Direct drive system option

Belt width (in) 28 30 32 36 42 44 48 52

Usable belt width with

stainless steel belt (in)

25 27 29 33 39 41 45 49

Usable belt width with

plastic belt (in)

26 28 30 34 40 42 46 50

Tiers range 15 to 38

Tier pitch range (mm) 110 to 270

Available turn radius

Drum

diameter (in)

90 1,61 1,50 1,41 1,25 1,07 1,02

103 1,84 1,72 1,61 1,43 1,23 1,17 1,07

116 2,07 1,93 1,81 1,61 1,38 1,32 1,21 1,12

135 2,41 2,25 2,11 1,88 1,61 1,53 1,41 1,30

150 2,68 2,50 2,34 2,08 1,79 1,70 1,56 1,44

167 2,98 2,78 2,61 2,32 1,99 1,90 1,74 1,61

187 3,34 3,12 2,92 2,60 2,23 2,13 1,95 1,80

212 3,79 3,53 3,31 2,94 2,52 2,41 2,21

240 4,29 4,00 3,75

Configurable solutions to match different requirements

The standard spiral belt mechanisms are defined by belt width, turn radius, number of tiers and tier pitch.

• Overall belt widths are available from 28’’ to 52’’ to match those of typical processing lines.

• Modules can be configured with turn radius ranging from 1.1 to 4.3, dependent upon space constraints and

site footprint.

• A-Tec solutions can be supplied with 15 to 38 tiers, and single drum or twin drum configurations, to meet

just about any capacity.

• Tier pitch can be configured from 110 mm to 270 mm, to accommodate different product heights.

A-Tec spiral standard matrix

6 · GEA A-Tec

Frozen meat, poultry and fish

Products

Typical product dimensions L x W x H

[in]

Typical product weight

[oz]

A-Tec 28

capacity* [lb/h]

A -Tec 42

capacity* [lb/h]

Poultry Nuggets, battered and breaded, par-fried, frozen 1.5“ x 1" x 0.5" 1 1,700-6,600 6,600-14,000

Tenders, battered and breaded, par-fried, frozen 4" x 1" x 0.5" 1 1,900-6,800 6,100-14,000

Filets, battered and breaded, par-fried, frozen 5.5" x 3.5" x 0.75" 4 1,600-6,600 5,300-14,000

Nuggets, battered and breaded, fully cooked, frozen 1.5'' x 1" x 0.5" 1 1,500-5,500 4,800-14,000

Tenders, battered and breaded, fully cooked, frozen 4" x 1" x 0.5" 1 1,600-6,600 5,300-14,000

Filets, battered and breaded, fully cooked, frozen 5.5" x 3.5" x 0.75" 4 1,400-5,300 4,600-14,000

Meat Beef patties, raw, frozen 4"(D) x 3/8"(H) 4 1,500-6,500 4,800-14,000

Beef patties, fully cooked, frozen 4"(D) x 3/8"(H) 4 1,300-4,600 4,200-12,300

Meat ball, raw, frozen Sphere 1" 0.28 1,500-6,500 4,800-14,000

Meat ball, fully cooked, frozen Sphere 1" 0.28 1,300-4,600 4,200-12,500

Fish Filets, raw, frozen 8" x 3.5" x 0.5" 4 1,400-5,100 4,400-13,400

Fingers, battered and breaded, par-fried, frozen

4" x 1.25" x 0.6" 1 2,500-9,000 7,900-14,000

Filets, battered and breaded, par-fried, frozen

5.25" x 4" x 0.7" 6.6 2,500-9,200 8,100-14,000

* Capacity figures are indications for basic estimation purpose

Supporting innovative recipes and products

In today’s global food marketplace consumers expect their

supermarket fridges and freezers to offer tasty, high protein

meal choices for busy lives. Fast food outlets and restaurants

also expect the highest quality meats, poultry and fish for

their recipes. GEA’s performance equipment and solutions for

forming, frying, cooking, grilling and freezing, has allowed our

customers to develop innovative new processes and products to

meet changing market trends.

Locking in freshness

Products that have been formed, coated and heat treated need to

be preserved through chilling and freezing processes so that they

retain quality. GEA’s portfolio of A-Tec spiral freezers and chillers

can be configured to match your plant layout, loading patterns and

production capacity. Our technology uses horizontal air stream at

a precisely controlled temperature to surround every surface of

product, and ensure that freshness, weight, appearance and taste

are retained. Designed to be space-saving and compact, GEA’s A-Tec

spiral freezers and chillers guarantee optimum hygiene, and are

built around state-of-the-art refrigeration and freezing technologies

to ensure reliability and efficiency, reduced freezing times and

lower energy consumption. Our customers save on energy costs,

time, and ultimately cost per pound.

A-Tec chillers and freezers use industry-leading horizontal airflow technology to surround every surface of the product.

GEA A-Tec · 7

Bakery products

Advanced technologies and specialist support

The bakery sector relies on advanced technologies to ensure

flawless product handling at every stage, from proofing to

cooling and freezing. Whether you are producing waffles,

pancakes, baked bread, cakes or pizzas, we understand that

your primary objective is to retain optimal quality and preserve

product shape, texture, and color. Our application specialists

can help you to select energy efficient, sustainable cooling and

freezing solutions that will best meet your key product and

process requirements.

GEA technologies offer many advantages:

• Precisely controlled air temperature prevents freezer burn

• Gentle product handling minimizes belt marking

• High uptime with up to 14 days continuous operation

• Efficient, effective frost management system

• Configurations for high capacity, and up to 8’’ product height

Our engineering experts will consult with you to develop

technical solutions that will help to ensure maximum reliability

and optimal performance. Our superior horizontal airflow

technology provides the most efficient heat transfer to the

product while minimizing energy consumption.

GEA proofing, chilling and freezing technologies gently handle your bakery products to preserve shape, texture and color.


Products Typical product

dimensions L x W x H [in]

Typical product

weight [oz] GEA A-Tec solution Product treatment

Capacity range* [lb/h]

Waffle4.5”(D) x 0.75“(H) 1.34

Double drum A-Tec DDS

spiral freezer

Freezing from +190°F

to -10°F2,000-6,500

Subway roll11.0” x 1.25” x 1.25” 6.5

Single drum A-Tec DDS

spiral freezer


to 0°F2,200-14,000

French toast4.25” x 4.25” x 0.75” 2.5

Single drum A-Tec DDS

spiral freezer


to 0°F2,000-6,000

Baked bread

10" x 3.5" x 2.7" 16

A-Tec spiral ambient

cooler. Single drum or

twin drum

Cooling from +195°F

to +110°F

2,200-6,600Single drum A-Tec spiral

freezer with sequential

defrost for 6 days

in operation


to +10°F

Croissants

6" x 1.6" x 1.4" 2.6Double drum A-Tec

spiral proofer

Proofing: adjustable

air temperature from

+75°F to +105°F.

adjustable air humidity

from 70% to 90%

2,200-14,000

Cookie dough2.5“(D) x 1.5“(H) 1.7

Single drum DDS

spiral freezer

Freezing from

+70°F to 0°F2,000-20,000

Pancakes5”(D) x 0.46”(H) 1.83

Single drum lo-tension

spiral freezer

Freezing from

+140°F to 0°F2,000-6,000

Pizza with topping12“(D) x 2“(H) 33

Double drum A-Tec DDS

spiral freezer

Freezing from

+40°F to 0°F3,000-30,000

8 · GEA A-Tec

Ready meals

Perfect solutions for prepared meals

Ready meals became popular in the 1950s when families would

gather round the television and eat ready-prepared ‘TV dinners’

on trays with peel-off lids. Things have come a long way since

then, and the ready meals market is now focused on using

fresh, healthy ingredients and recipes, with fewer preservatives,

additives, salt and fat.

GEA is offering a wide range of equipment for ready meal

preparation lines including forming, slicing, cooking prior to

chilling or freezing. GEA can configure the ideal A-Tec freezing

and chilling solution for every type of ready meal product,

from in-flight meals and sandwiches, to soups and pasta. Our

technologies ensure that your products keep their quality, taste

and appearance, whether packaged in containers with or without

lids, in bags, trays, boxes or pouches.

Energy saving solutions

GEA chilling technology precisely controls and monitors the

ambient temperature to prevent surface freezing. The horizontal

airflow is more effective than vertical airflow for large trays,

as all surfaces of the product container are evenly surrounded

by air at the correct temperature. GEA freezers and chillers

also offer optimum energy efficiency, so that our customers

can be assured of cost savings, while improving environmental

sustainability.

GEA can configure A-Tec freezing and chilling solutions for any type of ready meal, from in-flight dinners and prepacked sandwiches, to soup and pasta.


Products

Typical product dimensions L x W x H

[in]


[oz]

GEA A-Tec solution

Product treatment


Meal tray

7.5” x 5.75” x 1.5“ 10

Double drum

A-Tec DDS

spiral freezer

Chicken and Sauce

at +45°F, Rice at

+90°F to 0°F

2,000-10,000

Corn dog

2" Dia. x 4" includes

2/3/8" stick2.67

Single drum

A-Tec DDS

spiral freezer


to 0°F2,000-12,000

Soup in pots

4'' Dia. x 5.5'' 21

Single drum

A-Tec DDS

spiral freezer


to 0°F2,000-12,000

GEA A-Tec · 9

Dairy applications

Precise temperature control for safe, tasty products

GEA supplies both small manufacturers and industrial-scale

producers with high tech equipment for homogenizing,

separating, metering, filling, chilling and freezing all types of

raw milk and milk-based dairy goods. Backed by decades of

experience working with dairy processing industry, we design,

engineer, equip and install complete plants. Processing safe,

fresh-tasting frozen and chilled dairy products depends on

hygienic equipment and reliable processes.

Consumers expect a wide choice of ice creams, cheese and yogurts

for every day, and for those special treats. GEA chillers and

freezers are designed to provide the exact temperature to milk-

based products during every stage of processing, to preserve

their texture and appearance. Our freezing technologies ensure

that ice cream is frozen quickly and uniformly to form small ice

crystals for perfect consistency. The temperature in our chillers

is finely controlled and monitored to ensure that dairy products

such as cheese retain their perfect form and texture.

Improve shelf-life and reduce waste

GEA’s chilling and freezing systems ensure top product quality,

which improves product shelf-life and reduces waste, while our

energy efficient technology reduces energy use and costs. And of

course, GEA’s spiral freezer and chiller solutions meet the most

stringent hygiene requirements. We construct our equipment

with fully welded floors, enclosures and conveyors, together

with full zone recirculating cleaning system. The option of fully

welded enclosures means that the equipment can withstand

160°F heat treatment for pasteurization.

A-Tec freezer and chiller technologies ensure that every milk, cream and cheese-based food is processed at the optimum temperature to retain flavor and increase shelf-life.


Products

Typicalproduct

dimensions L x W x H

[in]


[oz]

GEA A-Tec solution

Product treatment


Ice cream

14" x 10" x 4" 145Double drum A-Tec

DDS spiral freezer


to 0°F3,000-15,000

Milk curds

15" x 18" x 4" 335Single drum A-Tec

spiral chiller

Chilling from +95°F

to +40°F3,000-10,000

Pizza cheese

13" x 12" x 4" 353Double drum A-Tec

spiral chiller

Chilling from +95°F

to +50°F3,000-10,000

10 · GEA A-Tec

Spiral drive options

Lo-tension stainless steel

Lo-tension plastic Direct drive system plastic

Belt options

Cleaning system options

Full recirculating cleaning system

FIP (foam-in-place)

Top drive Bottom chain drive Low profile top drive

Modular configuration

Benefits for customers include fast installation on site, flexibility to adapt to space constraints, efficient, resource-saving cleaning and reduced maintenance.

Customized to specifications

GEA A-Tec spiral freezer solutions have been developed around

a proven modular concept, and can be configured to fit in

with any existing plant layout, capacity, and upstream and

downstream processes. Available in standard belt widths to

match typical food applications, A-Tec freezers can be supplied

with the optimum turn radius, number of tiers and pitch to meet

any process requirement, and are constructed to offer optimum

hygiene and cleaning system options.

High hygienic design and ease of maintenance

GEA A-Tec spiral freezers are supplied with modular, fully

welded flooring that doesn’t require floor heating, and helps

to ensure that there are no dirt traps that might compromise

hygiene. The option for fully welded stainless steel enclosure

panels removes the need for silicone joints, which aids

compliance with the most stringent hygiene requirements, eases

maintenance and makes thorough cleaning easier and faster.

Installing fully welded enclosures also makes it possible to apply

heat treatment up to 160°F.

GEA A-Tec · 11

Floor

Enclosure options

Frost management options

Shift defrost Sequential defrost Static Pressure Control System (SPCS) as standard

Fully welded White inside/white outside

Stainless steel inside White outside

Stainless steel inside Stainless steel outside

Fully welded modular as standard

Fan motor option

External fan motors

A-Tec spiral freezer technology features proven external drive

configuration, and the option for external fan motors. External

motors reduce the number of component surfaces within the

unit, which also helps to maximize hygiene, and makes cleaning

and maintenance much easier, particularly if the inside of the

freezer is running at -25°F.

A-Tec freezers can be configured to match height

requirements or restrictions, and can be equipped with a

top spiral drive, bottom chain drive or low profile top drive

(LPTD). The LPTD is located on the top of the freezer but is

driven by a gearbox positioned externally on the side of the

freezer. This configuration reduces the overall height of the

unit by around 63 inches for plants where headroom is

an issue.

12 · GEA A-Tec

Straight-through 90° turn 180° turn

Belt configuration

Drum configuration

Single Drum

Up-go

Double Drum

Infeed and outfeed

at the same level

Single Drum

Twin-belt with two

separate infeed lines

Single Drum

Down-go

Process flow design

Comprehensive spiral configuration options for perfectintegration in your processing line.

Every GEA A-Tec spiral freezer is designed to fit in with

upstream and downstream processes and in accordance

with plant layout and available space.

Freezer infeed/outfeed orientation, and spiral orientation

can be configured to make your process lines seamless and

efficient, and to ensure fast installation with less down time

and with minimal disruption to the rest of the line.

A-Tec freezers reduce total cost of ownership

All GEA equipment is designed for robust, maintenance-friendly

operation. Industry-leading evaporator technology reduces

energy consumption, and our configurable cleaning system

options reduce water usage. Our spiral freezer technology is also

constructed using non-proprietary parts that guarantee minimal

maintenance over a 10 year period, which further increases cost-

effectiveness. GEA customers can have complete confidence in

the reliability of all our systems right from day one, and for the

whole lifespan of the equipment.

GEA A-Tec · 13

14 · GEA A-Tec

At the GEA Technology Center, model simulations are built to optimize airflow and heat transfer for all spiral series.

Training programs by GEA experts

Experienced product application team at your service

Our application experts can test your products using our in-

house freezing test facility before you invest. Our Technology

Center located in Richmond, BC, Canada, offers a wide range of

freezer and chiller equipment, and configurable air temperature

and airflow conditions to match your processing needs.

We offer comprehensive hands on training and product

test programs to support your operational requirements.

Data collected during testing can be analyzed by our technology

experts to help you to select the right process conditions for

your product. We can even ship testing units to your site for

product trials under the correct production conditions.

Technology Center

Customer satisfaction is our main objective

GEA A-Tec · 15

GEA Service – For your continued success

Our focus is to build, maintain, and improve customer performance

throughout the entire life cycle of the plant and its equipment.

Beginning of Life Services

Getting you started with seamless support for instant productivity and performance

Lifetime Services

Keeping it running with the cost-efficient way of ensuring safety and reliability

Extended Life Services

Constantly improving by sharing our knowledge to safeguard your investment

Consulting & Enhanced Operations

Together with you by enduring commitment to you and your business

Working with GEA Service means partnering with a dedicated team of service experts.

Made to the minute. Every hour, every day, with GEA Service.

GEA is one of the largest technology suppliers for food processing and a wide range of other industries. The global group

specializes in machinery, plants, as well as process technology and components. GEA provides sustainable solutions for

sophisticated production processes in diverse end-user markets and offers a comprehensive service portfolio.

The company is listed on the German MDAX (G1A, WKN 660 200), the STOXX® Europe 600 Index and selected

MSCI Global Sustainability Indexes.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA Group

Aktiengesellschaft

Peter-Müller-Straße 12

40468 Düsseldorf, Germany

Tel +49 (0)211 9136-0

Fax +49 (0)211 9136-31087

gea.com/contact

gea.com 0820

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gea a-tec spiral freezers and chillers · 2020-05-19 · spiral freezers and chillers guarantee...

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